What is TPM? How to Implement TPM? Benefits of implementing TPM.

History of TPM

Between 1950 and 1970, Seiichi Nakajima invented TPM in Japan. The concept of preventive maintenance, on the other hand, was borrowed from the United States. In 1960, Nippondenso, a business that made parts for Toyota, was the first to implement plant-wide preventive maintenance. They were the first people to win the PM prize.

The JIPM created an internationally recognized TPM benchmark. As a result, Seiichi Nakajima is known as the father of TPM. Preventive maintenance is a concept in which operators produce things using machines and the maintenance group is tasked with keeping those machines in working order. The goal of productive maintenance is to increase the efficiency of plants and equipment in order to achieve the desired results.

What is TPM?

TPM stands for Total Productive Maintenance, and it began as a method of physical asset management aimed at maintaining and improving manufacturing machinery in order to lower an organization's operating costs. It is a systematic approach to reducing waste associated with production equipment and machinery.

TPM focuses on involving the machine operator in routine checks and cleaning of the machine to detect problems sooner. Other areas of focus include reducing machine "downtime" due to unforeseen malfunctions, maximizing a machine's capabilities, and tracking life cycle costs. In a nutshell, total productive maintenance (TPM) is the practice of utilizing machines and equipment to get the most out of them.

TPM Pillars

TPM is built on eight pillars based on Nakajima's 5-S approach. The 5S foundation (Sort, Set in Order, Shine, Standardize, and Sustain) is the foundation of TPM. To improve equipment reliability, the eight pillars of total productive maintenance rely on proactive and preventative maintenance procedures.

Autonomous maintenance, targeted improvement (kaizen), planned maintenance, quality management, early equipment management, training and education, safety, health, and the environment, as well as TPM in administration, are the eight pillars. Let's take a closer look at each pillar individually.

1. Autonomous Maintenance: Autonomous maintenance entails ensuring that your operators are thoroughly trained in normal maintenance tasks such as cleaning, lubricating, and inspecting, as well as entrusting them completely with that obligation. This offers machine operators a sense of ownership over their machines and improves their knowledge of the specific machine.

It also ensures that the machinery is always clean and lubricated, aids in the early detection of problems before they turn into failures, and frees up maintenance personnel to focus on higher-level jobs. Autonomous maintenance can be defined in a few phrases. Equipment operators are in charge of simple preventive maintenance chores.

2. Focused Maintenance: The Japanese concept "kaizen," which means "improvement," is the foundation of focused improvement. Kaizen in manufacturing entails continuously improving functions and processes. Focused improvement considers the entire process and generates suggestions about how to improve it.

TPM requires small teams to adopt a proactive mindset of working collaboratively to achieve regular, incremental changes to equipment operation processes. Through cross-functional brainstorming, it is possible to identify recurring problems by diversifying team members. It also brings together feedback from across the organization, allowing teams to see how processes affect other areas.

Furthermore, focused improvement improves efficiency by reducing product defects and the number of operations, while also improving safety by examining the risks associated with each individual action. Finally, focused improvement guarantees that improvements are consistent, reproducible, and long-lasting.

?3. Planned Maintenance: Studying measurements like failure rates and past downtime, then scheduling maintenance work around these projected or measured failure rates or downtime times, is what planned maintenance entails.

In other words, because equipment maintenance must be performed at a specified time, you can schedule it during times when the equipment is idle or producing at a reduced capacity, ensuring that production is not disrupted. In addition, planned maintenance allows for inventory to be built up in preparation for scheduled maintenance.

Because you'll know when each piece of equipment is due for repair, keeping this inventory on hand will ensure that any production loss due to maintenance is minimized.

4. Early Equipment Management: The TPM pillar of early equipment management applies the practical experience and general understanding of manufacturing equipment gained via total productive maintenance to the design of new equipment. Suppliers can improve maintainability and the way the machine performs in future designs by incorporating feedback from those who use it the most.

It's crucial to talk about topics like cleaning and lubrication ease, part accessibility, ergonomically positioning controls in a way that is pleasant for the operator, how changeovers happen, and safety features when discussing equipment design This method improves efficiency even further because new equipment already fits the intended standards and has fewer startup concerns, allowing it to reach planned performance levels faster.

5. Quality Maintenance: All of your maintenance planning and strategizing will be for naught if the quality of the work you're doing isn't up to par. The quality maintenance pillar focuses on detecting and preventing design errors in the manufacturing process.

It accomplishes this by identifying and eliminating recurrent sources of faults through root cause analysis (particularly, the "5 Whys"). Processes become more dependable by proactively discovering the source of mistakes or flaws, resulting in goods that meet requirements the first time.

The most significant advantage of quality maintenance is that it stops defective items from advancing farther down the line, potentially resulting in a lot of rework.

6. Safety, Health, and environment: Maintaining a safe working environment ensures that employees may complete their responsibilities without risking their health. It's critical to create a workplace that boosts productivity, but it shouldn't come at the expense of an employee's safety and health.

To accomplish this, all TPM solutions should constantly take safety, health, and the environment into account. Apart from the apparent advantages, when employees arrive at work each day in a safe environment, their attitude improves since they are not concerned about this important component. This can result in a significant boost in production. Safety should be prioritized during the early stages of the project.

7. Training and education:? A TPM program can be derailed by a lack of equipment expertise. Operators, managers, and maintenance employees all benefit from training and education. They are designed to ensure that everyone understands the TPM process and to fill in any knowledge gaps so that TPM objectives may be met.

This is where operators learn how to maintain equipment and spot problems before they become serious. Managers study TPM principles, staff development, and coaching, while the maintenance crew learns how to implement a proactive and preventative maintenance schedule. Single-point lessons put on or near equipment can assist personnel to learn more about operating procedures.

8. TPM in administration: ?The sum of its pieces determines the quality of a TPM program. By addressing and eliminating waste in administrative operations, total productive maintenance should extend beyond the plant floor. This entails improving order processing, procurement, and scheduling in order to support production.

Because administrative operations are frequently the initial stage in the manufacturing process, they must be efficient and waste-free. For example, if order-processing operations are improved, the material is delivered to the plant floor faster and with fewer errors, reducing the risk of downtime while missing components are located.

How to implement TPM Pillars

Select a Pilot Area

You may concentrate on a piece of equipment that is easy to upgrade or a production area that has been shown to be problematic and requires immediate attention in order to boost profitability. Identify SMART targets in this first step of the TPM process: Specific, Measurable, Attainable, Realistic, and Timed.

?Which is the most troublesome? Fixing the equipment that causes the greatest problems for operators will be positively appreciated, bolstering support for the TPM program. However, this strategy may not provide as much immediate gratification as the previous one, and it may be difficult to get a speedy result from solving an unsolved problem, leading to boredom.

?What is the most straightforward to improve? Selecting the easiest to modify equipment allows you to see rapid and positive outcomes; however, it does not put the TPM process to the test as thoroughly as the other two options.

Concentrate on repairing specific equipment to working order:

Once your pilot area has been determined, establish a current productivity baseline. Organize and define your TPM implementation strategy. Make use of the 5S technique (Sort, Set, Shine, Standardize, Sustain). Prioritize implementing an autonomous maintenance program and, as needed, providing training to equipment operators.

Companies can extend equipment lifespans and uncover mechanical concerns early on by allowing their personnel to participate in basic maintenance operations on a regular basis, just as a car owner can save a considerable amount on repair expenses by completing basic routine maintenance.

?Taking pictures of the area and the current state of the equipment, then publishing them on your project board and photographing and putting on the project board the changes to the equipment and surrounding area.

? Keeping track of the tools and components you use on a regular basis (a shadow board with tool outlines is a popular option).

? Establishing a standardized 5-S work procedure to ensure the process's continuity.

? Cleaning up the area by getting rid of any unneeded tools, rubbish, or anything else that could be deemed trash and thoroughly cleaning the equipment and the surrounding area.

Begin to assess the overall equipment effectiveness (OEE)

It is critical that unplanned halt times are documented and a justification given for each occurrence, regardless of how you keep track of OEE. For circumstances where the operator is unsure of the stop cause, create a category called "unknown cause" or "unallocated stop time." To acquire an accurate representation of unexpected stoppage time and a clear image of how shortstops and slow cycles affect productivity, you should collect data for at least two weeks.

A basic example of a top 5 loss chart is shown below. Each loss is categorized and listed in descending order from the most downtime-causing loss to the least downtime-causing loss.

Reduce or address major loss causes

You'll need to form a cross-functional team of 4 to 6 employees to explore one primary cause of downtime at this stage. This group will devise a strategy for eliminating the loss source and set aside time to carry out the endeavor.

For example, if frequent filler jams are causing significant losses, this team will analyze current operator methods and repair possibilities, devise a strategy to eliminate the jams, and schedule time to put the plan into effect. They will measure OEE moving ahead and redo the process if necessary once the assigned action has been done.

Implement organized maintenance

The goal of this phase is to prevent breakdowns or halt times. Identify important "pain points" that potentially lead to equipment failure and develop a preventative maintenance schedule that can be followed at regular intervals. Finally, establish a feedback system that will allow you to track the effectiveness of your program over time. Designing a feedback system can help you improve maintenance intervals.

Log sheets for each wear-and failure-prone component, on which operators can record replacement information as well as component status at the time of replacement, will be critical. Conduct monthly planned maintenance audits to ensure the maintenance schedule is being followed and the components are in good working order.

As needed, apply specific TPM concepts

When developing and/or installing new machines for the manufacturing floor, for example, early equipment management should be considered. Perhaps improved accessibility, quicker cleaning or lubricating procedures, or the addition of safety elements should be included in the design of new equipment.

If, on the other hand, there are procurement concerns or delays in processing work orders, these administrative bottlenecks should be addressed as quickly as possible.

Benefits of TPM

Safe Environment: TPM is based on Lean's 5S approach's structured management framework. Sorting, putting things in order, shining, standardizing, and sustaining are the five things in consideration. The five points all lead to the premise that keeping equipment and machinery clean, organized, and healthy can increase workplace safety.

TPM's emphasis on proactive and preventative maintenance extends the life of equipment while also reducing workplace chaos. It also makes it easier to create designs that boost productivity, efficiency, and flow. All of these characteristics serve as the foundation for worker safety at all levels.

Efficiency: The TPM approach's main goal is to achieve "perfect production," as it's commonly referred to. In other words, any company that uses TPM aspires to have no defects, breakdowns, or accidents. As a result, you may need to prioritize quality over quantity, as well as efficiency over output.

Measuring Overall Equipment Effectiveness is one tool offered to manufacturers implementing productive maintenance (OEE). This statistic, which is computed by looking at Availability x Performance x Quality = OEE, assists manufacturers in identifying areas where they may increase their operations' effectiveness and efficiency. Operational efficacy and efficiency. It supports improvement by promptly detecting any areas of loss, comparing progress, and increasing equipment productivity, all based on complete data.

Moral: To properly execute lean manufacturing, you'll need personnel at all levels of your organization to completely embrace the concept. If it shows positive outcomes, employees are less inclined to fight the changes. TPM is comparable in many ways: employees are given the obligation to care for their equipment through its principles. As a result, they may take pride in and ownership of their work.

TPM's preventive measures result in fewer instances of equipment failure and less irritating downtime. Your employees' dedication to the TPM philosophy will only grow as a result of these successes.

Satisfaction of customers Increased: The benefits of productive maintenance include a safe workplace, high staff morale, and efficient production. Many would argue, however, that in the long run, customer experience and satisfaction are more crucial. The TPM pillar of quality maintenance enables quality improvements to be integrated into the manufacturing process.

As a result, there are frequently fewer reworks and defects, as well as higher output and quality. This, combined with dependable machinery with years of experience, makes for a winning combination. Adopting a whole productive maintenance plan produces efficient output, high staff morale, and a safe workplace.

?Conclusion

Today, with industry competition at an all-time high, TPM may be the only thing that separates some businesses from outright disaster. It has been demonstrated to be a successful program. It can be used in a range of settings, including industrial facilities, construction, building maintenance, transportation, and a variety of others.

Employees must be informed and convinced that TPM is not just another "program of the month," and that management is fully committed to the program and the lengthy implementation period. If everyone who participates in a TPM program does their part, an extraordinarily high rate of return on investment can be expected.

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